Explosive Chemicals Research Laboratory should
minimally have the following in place:
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A Chemical Hygiene Plan
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An Explosive Safety Plan
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Laboratory Facility Requirements
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PPE Plan
Guidelines to handle, label and store hazardous
laboratory chemicals based on characteristics
 Identify and understand the chemical and physical
hazards (MSDS; literature).
 Safety protocols to reduce exposure, injury from
violent reactions.
 Required Personnel Protective Equipment
 Location and use of emergency equipment
 Emergency procedures: fire and chemical spill,
explosion
 Consistent appropriate labeling
 Safely dispose of chemical waste (environmental as
well as compatibility)
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Strict explosives and personnel limits
Approved and signed Standard Operating
Procedures (SOPs) for all explosives operations
 Training Program for explosives laboratory
personnel
 Peer Review System for use of new energetic
materials and explosives processes and operations
 Energetic materials facilities explosives safety
requirements
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1998 NSWC IHDIV.(Naval Surface Warfare Center (IHDIV,
NSWC)). Powder ignition by ESD. No injuries, some
equipment damage. Root cause: SOP and facility needed
update for controlling ESD.
 2009 NSWC IHDIV. Spontaneous Ignition of
Nanoaluminum perfluorotetradeconoic acid. Severe burns.
Root cause: operator deviated from approved Lab Review
Form.
 2010 TTU. Nickel hydrazine perchlorate synthesis.
Explosion with critical injury: student lost three fingers, his
hands and face were burned, and one of his eyes was
injured after the chemical he was working with detonated.
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The physical hazards inherent in the research were not effectively
assessed, planned for, or mitigated
The university lacked safety management accountability and
oversight
Strict explosives limits never followed
Previous incidents with preventative lessons were not documented,
tracked, and formally communicated
The funding agency, with a control over the research did not
prescribe any safety provisions
OSHA standards and guidelines have been developed to promote
hazard evaluation methodologies in an industrial setting, similar
resources that address the unique cultural and dynamic nature of an
academic laboratory setting have not been generated
OSHA standard was not created to address physical hazards of
chemicals, but rather health hazards
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Division 1.1 – mass explosion hazard,
Division 1.2 – projection hazard but not a mass explosion
hazard.
Division 1.3 – fire hazard and either a minor blast hazard or
minor projection hazard or both, but not a mass explosion
hazard
Division 1.4 – minor explosion hazard. The explosive effects
are largely confined to the package and no projection
Division 1.5 – Very insensitive explosives that have a mass
explosion hazard but are so insensitive that there is little
probability of initiation or of transition
Division 1.6 – Extremely insensitive articles that do not
have a mass explosive hazard and that contain only
extremely insensitive detonating substances
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Primary explosives: can be initiated by dropping,
impacting, friction or electrostatic discharge. E.g..
Mercury fulminate, lead azide, lead styphnate
Secondary explosives: sensitive to heat, shock,
impact, friction, ESD. Examples of military high
explosives: TNT, RDX, HMX, C4,
Propellants: nitrocellulose (single base),
nitrocellulose and nitroglycerine (double base),
nitrocellulose/nitroglycerine/nitroguanidine
(triple base), ammonium
perchlorate/aluminum/binder (composite)
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Restrict the number of personnel and amount
of energetic material to the lowest possible
minimum at all times
Dedicated laboratory with posted explosive
limits.
Never store excess material: minimum
required for the operation present in the
laboratory at the time of the operation.
Two man rule: never work alone.
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Mandatory training for everyone working
directly or coming in contact with energetic
material
Established training programs for certification
Documentation of the training
Must be qualified to understand the SOP
Update training and reinforce good habits
with refreshers
All operations shall be performed in accordance
with written and signed Standard Operating
Procedures.
– materials
– laboratory equipment
– experimental procedures
– detailed hazard analysis
– safety requirements and risk mitigation
– signature page signed by managers and
certified operators

Written Standard Operating Procedures for the general
operation and energetic materials handling
requirements
– site diagram, explosives and personnel limits, – hazardous
chemicals used, – safety and process equipment, –
documentation requirements, – PPE, housekeeping, use of
fume hoods
 Signed and approved by responsible departmental
parties and Office of Environmental Health and Safety
 Signed by Process Supervisor and Workers
 Signatures along with validation statement to have read
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and understand the SOP.
Documentation required before conducting the
explosive operation, – Laboratory Notebook, –
Lab Review Form, – Process Review Form, –
MSDS on file
 Detailed procedure in written detail, – Reactions,
– Chemicals reagents required, – Step-by-step
procedure, – Special equipment required
 Signed by responsible manager or designee
 Copy on file in department office and at work
site
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Peer review ensures that safety concerns of
new materials, processes, equipment, and
operations are addressed by more than one
competent professional.
Process Review Committee
Operations Safety Committee
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Designated laboratory for explosives
operations with posted explosives and
personnel limits
Locked when unattended. Controlled access
when operations are in place
‘Red/Green’ placard at the door to indicate
‘explosives present’ or ‘no explosives present.’
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Laboratory energetic materials storage: – store
behind shielding, – explosive proof refrigerator, –
limited amounts; do not store excess, – store in
Velostat bags or containers; never glass with
screw top caps.
Laboratory energetic materials handling: –
conductive mats, conductive bench top or
grounded steel tops, – use wooden in place of
metal spatulas, – paper filters; never sintered
glass filters, – teflon sleeves on rotovap
do not grind with mortar and pestle; grind with
ball-mill or other approved remote procedure.
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Storage of Explosive Hazardous Waste (EHW).:
– Store EHW behind a shield, – Limit storage
of EHW to no more than one week, – Avoid
overnight storage of EHW
Shielding Requirements
Determine appropriate grounding policy and
explosion proofing for unique electronic
equipment.
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To avoid accumulation of static charge on sensitive
materials follow the below guidelines:
 Ensure all electrical equipment is grounded.
 Do not wear nylon or other synthetic fabrics that possess the
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tendency to build up static charges.
Keep concentrations of solvents and dusts in the air as low as
possible.
Store extremely static sensitive materials only in grounded
containers
Perform work with static sensitive materials on conductive
surfaces.
Keep the humidity in the atmosphere to the appropriate level
for the material being handled (40-60 percent humidity).
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Safety Precautions: Necessary precautions must
be taken when present or working
• Observe personnel and explosive safety limits
• Note of chemicals, explosives, propellants, oxidizers
used or present in the laboratory.
• Reminder that energetic materials can be activated in
four ways: friction, electrostatic discharge, impact, and
heat.
• Requires appropriate protective safety clothing and
equipment
• Observers and visitors refrain from handling materials
when they are not certified on an SOP
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Safety Precautions: Necessary precautions must
be taken when present or working in the
laboratory:
• Identify hearing protection, gloves, and respirator for
specific operations as necessary
• When working with exposed, solid ESD sensitive or
uncharacterized energetic materials wear conductivesole shoes, or leg stats and stand on a conductive mat.
• Identify exits and muster points in case of an
emergency
• Identify location of cleanup equipment in case of a
spill
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Separate the experimental setup with proper shielding and an additional
safety screen in the fume hood.
Cover the glassware with adhesive films to reduce the fragmentation in
case of explosions,
In addition to lab coat, gloves, safety glasses wear a face protection shield,
ear protection, a leather jacket with arm protection.
For hand protection use leather gloves (welding type), ideally in
combination with steel interwoven Kevlar® gloves
Start the first experiments on a small scale of only a few mg and increase
the scale gradually
Keep solid material wet or soaked with solvent as long as possible.
Try to obtain solid products of small particle sizes. Smaller particles/crystals
are less sensitive to mechanical stress. Recrystallization experiments should
thus be cooled down very quickly under stirring.
Do not use metal, use spatulas made of wood or Teflon®.
Keep sufficient distance between the material and your body. Do not touch
the potential explosive material directly and use gripping devices to
maneuvre the container that encloses the compound.
Wear ESD protective clothing and antistatic shoes. The laboratory floor
should be ESD conductive
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Regular group inspections conducted by
responsible parties to identify deficiencies
and record findings (Inspection Team):
• Supervisor, Team Leader, Worker
• OEHS representative
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Corrective action plans are submitted within a
given time frame to address findings.
Enforcement may be needed to correct
negligence (loss of certification).
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The following become explosive-hazardous waste
when discarded. The EPA waste code is D003.
• Energetic
materials
(i.e.,
propellant,
explosives,
initiators)
• Rags and solvents contaminated with energetic
materials
• Do not store explosive contaminated liquids in screw
cap containers
• Explosive solid waste stored in conductive Velostat
bags
•
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Establishing an ESD task force to outline the
requirements of the program, implement the
program, review progress against milestones, and
follow up to ensure the program is continuously
improved and upgraded.
Conducting a facility evaluation to help identify the
sources of ESD and establish
static control
measures.
Setting up an audit program.
Selecting ESD protective materials and equipment.
Establishing a training and ESD awareness program.
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Grounding
Wearing foot straps and testing them before entering
the protected area
Conductive flooring
ESD Policy
Mobile carts have conductive wheels and drag chains
Conductive chairs
Unneeded items are not brought in to the ESD
protected area. Everyone who enters the area must
abide by the rules for the protection to be effective.
DO NOT enter these areas without proper
understanding of the ESD control procedures
implemented in the area.
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Conductive flooring
Dissipative work surfaces
Personal grounding
Grounded work benches
Conductive carts with drag chains
Conductive chairs
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Remove unneeded static objects from your
workstation - keep objects you need a safe distance
away from sensitive components and assemblies.
Use a topical antistat, if possible, to eliminate static
build up on objects that are necessary to do your job.
Minimize movement and friction.
Protect sensitive parts from the charges around them Use ESD protective packaging.
Place components and assemblies only on a dissipative
mat or dissipative work surface.
All personnel, surfaces and equipment must be
grounded to drain off any charges that are created.
Keep work surfaces clean and free of dirt build-up.
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Before you enter an ESD protected area you must
put on special footwear. This protective footwear
helps prevent static as you walk. Ground straps
allow the user to stay at or near ground
potential.
you must test the foot wear before you begin
work. Foot wear must be tested twice per day. At
the test station lift one foot and touch the tester.
Don't wear shoe grounders without resistors
around an exposed electrical hazard. Don't wear
shoe grounders at all around hazards that are
over 250 volts.
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The best prevention program is a combined
effort aimed at the prevention and the
controlled elimination of static charges,
through the practice of proper
behavior/procedures, workstation design and
layout, environmental controls, tooling and
component handling.
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Non-static generating clothing shall be worn
in ESD-protected areas or static dissipative
smocks shall be worn as an outer garment.
Finger cots and gloves, when worn in an ESDprotected area, shall be made of static
dissipate, lint-free, particle-free materials
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The relative humidity shall be monitored and
maintained in ESD-protected work areas at
30% to 70%. At levels below 30%, additional
precautions shall be employed (e.g. air
ionizers, humidifiers, etc.).
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ESDS items, equipment and assemblies shall
be identified so as to warn personnel before
any ESD damaging procedure can be
performed.
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Personnel grounding devices (such as wrist
straps) shall be supplied to all personnel
working with or handling ESD items to
prevent the accumulation of dangerous
electrostatic charge levels.
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The area shall maintained in a clean and
orderly condition. Smoking, eating and
drinking in ESD-protected areas shall not be
permitted. Unapproved tools, static
generating materials, and/or materials
unessential to the fabrication area are also
prohibited at the workstation.
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All work surfaces/workstations in an ESDprotected area shall be static dissipative and
electrically connected to the common point
ground system.
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The ESD-protected area shall be clearly
identified by prominently placed signs and
marking systems (barrier tape, partition, rope
guard, etc.). Access to such areas shall be
limited to trained and equipped personnel.
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Work surfaces
Waxed, painted or plastic surfaces.
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Floors
Waxed, common vinyl tiles, sealed
concrete
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Clothes
Common smocks, non-conductive
shoes, synthetic materials (e.g. nylon)
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Chairs
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Packaging
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Assembly area
Vinyl, fiber-glass, finished wood
Common plastic bags, foam, trays, tote
boxes
Spray cleaners, heat guns, blowers,
plastic tools (e.g. solder suckers,
brushes), cathode ray tubes.
Means of static generation
RH 10-20%
RH 65-90%
RH-Relative humidity
Walking across a carpet
35,000 V
1,500 V
Walking on a vinyl tile floor
12,000 V
250 V
Vinyl envelopes for work instructions
7,000 V
600 V
Worker at bench
6,000 V
100 V
Test
Item
Test Parameters
Verification Intervals
Daily
Weekly
Quarterly
1
Work
surface
≥ 1 x 106 ohms and < 1x 109
ohms
X
2
Protective
Floor
Resistance
< 1 x 109 ohms. After cleaning
the floor shall be checked
X
and the data recorded.
3
Protective
floor
grounding
> 1 x 105 and < 1x 109 ohm
from the floor surface to the
equipment ground.
X
4
Wrist strap
1 x 106ohms ± 20% or user
defined value
X
5
Foot wear
grounding
< 35x106ohms
X
Yearly
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Explosives chemical research requires additional
safety standards beyond a Chemical Hygiene
Plan.
Additional safety precautions are needed for
handling, storing, and disposing Class 1 explosive
materials.
Set number of personnel and amount of
energetic material to the lowest possible
minimum—minimize exposure in the designated
laboratory.
Designated laboratory for explosives operations
with posted explosives and personnel limits